Attachment structure of EA component

ABSTRACT

In an attachment structure of an EA component, the EA component composed of a synthetic resin such as rigid urethane foam is attached to a trim serving as a member, with a first locking part therebetween. The first locking part includes a cylindrical part, an anchor, a flange, and a plurality of projections. The anchor has a flange shape extending from the rear end of the cylindrical part toward the outside. The flange extends from the leading end of the cylindrical part toward the outside. The projections protrude from the leading end of the cylindrical part in the direction parallel to the axis of the cylindrical part. The EA component is attached to the trim by setting the EA component on the trim while the projections are inserted in an opening.

CROSS REFERENCE TO RELATED APPLICATION

This application is a 371 of PCT/JP03/12765 filed on Oct. 6, 2003.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an attachment structure of an impactenergy-absorbing (EA) component, and in particular, to an attachmentstructure of an EA component that can be suitably applied to a trim or aroof component of automobiles.

2. Description of the Related Art

For the purpose of the impact energy absorption (EA) in case of side-oncollision (i.e., side impact), an EA component composed of rigidurethane foam is attached to a door trim or a roof of automobiles. In amethod for attaching an EA component composed of rigid urethane foam toa door trim, Japanese Unexamined Patent Application Publication No.2001-322507 discloses the structure shown in FIGS. 3, 4 a, and 4 b. FIG.3 is a cross-sectional view showing the attachment structure of an EAcomponent disclosed in FIG. 7 in the above-cited patent document, FIG. 4a is a perspective view of a cylindrical body 20 used in this structure,and FIG. 4 b is a sectional perspective view of the cylindrical body 20.

The cylindrical body 20 includes a cylindrical part 21 and an overhangsection 22 that is integrated with the cylindrical part 21. A claw part23 is provided at the end of the cylindrical part 21 toward the insidedirection. A rod 26 is disposed on a trim 31 in an extending manner. Arecess 27 is provided at the periphery of the rod 26 and the claw part23 is engaged with the recess 27.

The cylindrical part 21 includes slits 24 extending from the leading endthereof in the direction parallel to the central axis. Accordingly, theshape of the cylindrical part 21 can be resiliently changed in theexpanding radial direction.

In order to attach an EA component 33 to the trim 31, the EA component33 is disposed on the trim 31 such that the rod 26 is inserted in anattachment hole 34 of the EA component 33. Subsequently, the cylindricalbody 20 is pressed on the attachment hole 34 so as to be engaged withthe rod 26, thereby engaging the claw part 23 with the recess 27. Thus,the overhang section 22 holds down the periphery of the attachment hole34 of the EA component 33.

The cylindrical part 21 has a tapered shape so as to be inserted in theattachment hole 34 easily. When the cylindrical body 20 is fitted to therod 26, the outer periphery of the cylindrical part 21 is closelycontacted with the inner periphery of the attachment hole 34.

In the above attachment structure of the EA component, the process forattaching the EA component on the trim 31 requires two steps including astep of disposing the EA component on the trim 31 and a subsequent stepof engaging the cylindrical body 20 with the rod 26. Therefore, thisprocess is time consuming.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide anattachment structure of an EA component in which the workability forattaching the EA component to a member such as a trim is significantlyimproved.

According to an attachment structure of an EA component of the presentinvention, in an attachment structure for attaching the EA component toa member, the EA component is attached to the member by engaging a firstlocking part that is integrated with the EA component with a secondlocking part provided in the member.

According to this attachment structure of an EA component, the firstlocking part is integrated with the EA component. Therefore, the EAcomponent can be attached to the member by a single step of engaging thefirst locking part with the second locking part of the member while theEA component with the first locking part is set in the member.

According to a first aspect, the first locking part may be resilientlydeformed, and when engaged with the second locking part, the firstlocking part may be resiliently deformed and may be then resilientlyrestored to engage with the second locking part. As a result, the firstlocking part can be readily attached to the second locking part.

According to the first aspect, the second locking part is preferably anopening. Such a second locking part composed of an opening can bereadily provided at a desired position. In such a case, the firstlocking part preferably includes a claw part engaged with the edge ofthe opening. In particular, the first locking part preferably includes aprojection projecting from the EA component and the claw part ispreferably provided on the side face of the projection in the projectingdirection. A plurality of the projections is preferably provided alongthe edge of the opening. According to this structure, the EA componentcan be attached to the member by setting the EA component in the memberwhile the projections are inserted in the opening. Furthermore, since aplurality of the projections is provided along the edge of the opening,looseness (backlash) of the EA component in the direction parallel tothe surface of the member can be prevented.

According to the first aspect, the first locking part preferablyincludes a flange and the edge of the opening is preferably held betweenthe flange and the claw part. The formation of the flange can preventlooseness (backlash) of the EA component in the approaching orseparating direction of the EA component and the member.

According to the first aspect, a base of the first locking part may beembedded in the EA component. This structure can increase the bondingstrength of the first locking part and the EA component. The base of thefirst locking part may be provided so as not to pierce the EA component.This structure can increase the characteristics of shock absorption bythe EA component in the vicinity of the first locking part.

According to the first aspect, the EA component is preferably composedof a synthetic resin, in particular, a foamed synthetic resin such asurethane foam. The first locking part can be strongly integrated withthe EA component composed of such a synthetic resin by embedding thebase of the first locking part.

In the production of such an EA component composed of a synthetic resin,the first locking part may be held with a die used for molding the EAcomponent by a magnetic force. In such a case, the molding can beefficiently performed. Furthermore, when the first locking part includesthe flange, the flange can be closely contacted with the die by themagnetic force, thereby preventing the generation of a burr.

This attachment structure of an EA component is preferably applied toattach a pad for the head protection or a pillar pad disposed along theinterior surface of an automobile cabin. However, the application of theattachment structure of an EA component is not limited to the above.

According to a second aspect, the EA component is attached to the memberby engaging a projection of the first locking part that is integratedwith the EA component with a second locking part provided in the member.In addition, the rear end portion of the projection is surrounded by asurrounding wall.

According to the second aspect, the rear end portion of the projectionis surrounded by the surrounding wall. Therefore, in the production ofthe EA component, this structure can prevent a material of the EAcomponent (for example, a foamed synthetic resin) from flowing in therear end portion of the projection.

According to the second aspect, the projection may be resilientlydeformed, and when engaged with the second locking part, the projectionmay be resiliently deformed and may be then resiliently restored toengage with the second locking part. As a result, the projection can bereadily attached to the second locking part.

According to the second aspect, the second locking part is preferably anopening. Such a second locking part composed of an opening can bereadily provided at a desired position. In such a case, the projectionof the first locking part preferably includes a claw part engaged withthe edge of the opening. In particular, the claw part is preferablyprovided on the side face of the projection in the projecting direction.A plurality of the projections is preferably provided along the edge ofthe opening. According to this structure, the EA component can beattached to the member by setting the EA component in the member whilethe projections are inserted in the opening. Furthermore, since aplurality of the projections is provided along the edge of the opening,looseness (backlash) of the EA component in the direction parallel tothe surface of the member can be prevented.

According to the second aspect, the first locking part preferablyincludes a flange, the projection and the surrounding wall arepreferably disposed so as to be projected from the flange, and the edgeof the opening is preferably held between the leading end of thesurrounding wall and the claw part. This structure can prevent looseness(backlash) of the EA component in the approaching or separatingdirection of the EA component and the member.

According to the second aspect, a base of the first locking part may beembedded in the EA component. This structure can increase the bondingstrength of the first locking part and the EA component. The base of thefirst locking part may be provided so as not to pierce the EA component.This structure can increase the characteristics of shock absorption bythe EA component in the vicinity of the first locking part.

According to the second aspect, the EA component is preferably composedof a synthetic resin, in particular, a foamed synthetic resin such asrigid urethane foam. The first locking part can be strongly integratedwith the EA component composed of such a synthetic resin by embeddingthe base of the first locking part.

In the production of such an EA component composed of a synthetic resin,the surrounding wall of the first locking part may be held with a dieused for molding the EA component by fitting. In such a case, themolding can be efficiently performed. Furthermore, since the surroundingwall can be closely contacted with the die, a urethane or the like doesnot flow in the inside of the surrounding wall, thereby preventing thegeneration of a burr.

This attachment structure of an EA component is preferably applied toattach a pad for the side impact disposed along the interior surface ofan automobile cabin. However, the application of the attachmentstructure of an EA component is not limited to the above.

A locking piece that can be used as the first locking part in the secondaspect includes a base embedded in the EA component; a flange providedat one end of the base; a plurality of projections projected from theflange, the projections being able to be resiliently deformed, and theprojections being inserted in an opening for attaching the EA component;claw parts provided on the side face of the projections, the claw partsbeing able to be engaged with the edge of the opening; and a surroundingwall projected from the flange in the same direction as that of theprojections, the surrounding wall surrounding the rear end portion ofthe projections. This locking piece is preferably used for the aboveattachment structure of an EA component.

According to a third aspect, the first locking part includes a grooveprovided in the inner periphery of a tube-shaped opening in thecircumferential direction. Such a first locking part having the groovecan be readily provided at a desired position. In such a case, thesecond locking part preferably includes a claw part engaging with theedge of the groove. In particular, the second locking part is preferablya projection projecting from the member and the claw part is provided onthe side face of the projection in the projecting direction.Furthermore, a plurality of the projections is preferably provided inthe circumferential direction of the groove.

According to this attachment structure of an EA component, the EAcomponent can be attached to the member by setting the EA component onthe member while the projections are inserted in the tube-shapedopening. Furthermore, since the plurality of the projections is providedalong the edge of the groove, looseness (backlash) of the EA componentin the direction parallel to the surface of the member can be prevented.

According to the third aspect, the edge of the groove is preferably heldbetween the member and the claw part. When the edge of the groove isheld by the member and the claw part, looseness (backlash) of the EAcomponent can be prevented in the approaching or separating direction ofthe EA component and the member.

According to the third aspect, most of the first locking part may beembedded in the EA component and only the leading end face of the firstlocking part may be projected from the EA component. This structure canincrease the bonding strength of the first locking part and the EAcomponent. The first locking part may be provided so as not to piercethe EA component. This structure can increase the characteristics ofshock absorption by the EA component in the vicinity of the firstlocking part.

According to the third aspect, the opening may have a cylindrical shape,a rectangular tube shape, or another shape. When the opening has arectangular tube shape, the second locking part inserted in therectangular tube substantially has a rectangular column shape.Accordingly, the second locking part can be readily molded.

In such a rectangular tube opening, a section of the rectangular tubeopening in the direction orthogonal to the central axis of the tube ispreferably a rectangle and the groove is preferably provided in thedirection of the long sides of the rectangle.

In particular, when the opening has the rectangular tube shape, the EAcomponent is preferably attached to the member with a plurality of pairsof the second locking parts and the first locking parts, and at leasttwo pairs of the second locking parts and the first locking parts arepreferably disposed such that the directions of the long sides of therectangle in the rectangular tube opening are orthogonal with respect toeach other. This structure can effectively prevent looseness of the EAcomponent in two orthogonal directions on the surface of the member suchas a trim.

When the opening has the rectangular tube shape, the width of the clawpart in the direction parallel to the groove may be smaller than thewidth of the groove. In such a case, even if the attaching position ofthe second locking part to the member or the attaching position of thefirst locking part to the EA component is somewhat offset from theintended position, the second locking part can be reliably engaged withthe first locking part.

According to the third aspect, the inlet of the tube-shaped opening mayhave a tapered shape gradually tapered toward the inside. In thisstructure, the second locking part can be readily inserted in the firstlocking part. In such a case, the end of the inlet of the tube-shapedopening may extend in the direction substantially parallel to thecentral axis of the tube.

According to the third aspect, a part of the EA component may be incontact with the member such as a trim. In such a case, the EA componentcan be stably attached to the trim or the like.

According to the third aspect, the EA component is preferably composedof a synthetic resin. The first locking part can be strongly integratedwith the EA component composed of such a synthetic resin by embeddingmost of the first locking part.

In the production of such an EA component composed of a synthetic resin,the first locking part may be held with a die used for molding the EAcomponent by a magnetic force. In such a case, the molding can beefficiently performed.

This attachment structure of an EA component is preferably applied toattach a pad for the side impact disposed along the interior surface ofan automobile cabin. However, the application of the attachmentstructure of an EA component is not limited to the above.

According to the third aspect, an EA component can be readily attachedto a member such as a trim. According to the present invention, thecharacteristics of shock absorption by the EA component can be improved.In addition, the EA component can be reliably attached to the memberregardless of the shape, the dimension, and the hardness of the EAcomponent.

According to an attachment structure of an EA component of a fourthaspect, a non-woven fabric serving as the second locking part ispreferably provided on the surface of the member, the surface to whichthe EA component being attached, and a planar fastener serving as thefirst locking part is preferably fixed on the surface of the EAcomponent, the planar fastener being integrated with the EA componentduring the molding of the EA component with foaming. In this attachmentstructure, the EA component is preferably attached to the surface of themember by entwining the planar fastener with the non-woven fabric.

According to the fourth aspect, the planar fastener is provided on thesurface of the EA component by integrating with the EA component.Therefore, the EA component can be attached by a single step of pressingthe EA component with the planar fastener on the surface to be attachedso as to entwine the planar fastener with the non-woven fabric providedon the surface.

Anchors of the planar fastener may be provided so as not to pierce theEA component. This structure can increase the characteristics of shockabsorption by the EA component.

The attachment structure of an EA component according to the fourthaspect is preferably applied to attach the EA component to a roof trimof an automobile. However, this attachment structure of an EA componentcan be applied to attach the EA component to other surfaces to beattached.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a cross-sectional view showing an attachment structure of anEA component according to a first aspect;

FIG. 1 b is a side view of a first locking part of the attachmentstructure of the EA component;

FIG. 2 a is a cross-sectional view showing a method for producing the EAcomponent with the first locking part of the first aspect;

FIG. 2 b is an enlarged view of a part of FIG. 2 a;

FIG. 3 is a cross-sectional view showing a known structure;

FIGS. 4 a and 4 b are explanatory views of the structure in FIG. 3;

FIG. 5 a is a cross-sectional view showing an attachment structure of anEA component according to a second aspect;

FIG. 5 b is a longitudinal cross-section of a locking piece of theattachment structure of the EA component;

FIG. 5 c is a perspective view of the locking piece;

FIG. 6 a is a cross-sectional view showing a method for producing the EAcomponent with the locking piece of the second aspect;

FIG. 6 b is an enlarged view of a part of FIG. 6 a;

FIG. 7 a is a cross-sectional view showing an attachment structure of anEA component according to a third aspect;

FIG. 7 b is a perspective view of a second locking part of theattachment structure of the EA component;

FIG. 7 c is a sectional perspective view of a first locking part of theattachment structure of the EA component;

FIG. 8 a is a partial perspective view showing the leading end of afirst locking part according to an embodiment of the third aspect;

FIG. 8 b is a partial perspective view showing the leading end of afirst locking part according to an embodiment of the third aspect;

FIG. 9 a is a partial perspective view showing the rear end of a firstlocking part according to an embodiment of the third aspect;

FIG. 9 b is a partial perspective view showing the rear end of a firstlocking part according to an embodiment of the third aspect;

FIG. 10 is a cross-sectional view showing a method for producing the EAcomponent with the first locking part of the third aspect;

FIGS. 11 a and 11 b are cross-sectional views showing an embodiment ofthe third aspect;

FIG. 12 a is a perspective view of a second locking part in FIGS. 11 aand 11 b;

FIG. 12 b is a perspective view of a first locking part in FIGS. 11 aand 11 b;

FIGS. 13 a and 13 b are explanatory views of an embodiment of the thirdaspect;

FIG. 14 is a cross-sectional view showing an attachment structure of anEA component according to an embodiment of a fourth aspect; and

FIG. 15 is a cross-sectional view showing a method for producing the EAcomponent with a planar fastener of the fourth aspect.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A preferred embodiment of a first aspect will now be described withreference to FIGS. 1 a to 2 b. FIG. 1 a is a cross-sectional view in thesubstantially horizontal direction showing an attachment structure of anEA component according to this embodiment. FIG. 1 b is a side view of afirst locking part of the attachment structure of the EA component. FIG.2 a is a cross-sectional view showing a method for producing the EAcomponent with the first locking part. FIG. 2 b is an enlarged view of apart of FIG. 2 a.

Referring to FIG. 1 a, a sheet-shaped EA component 1 composed of asynthetic resin such as rigid urethane foam is attached to a trim 2 (adoor trim in this embodiment) serving as a member, with a first lockingpart 3 therebetween. In this embodiment, an opening 4 serving as asecond locking part is provided in the trim 2. The first locking part 3is engaged with the opening 4. Although the opening 4 preferably has around shape, the shape of the opening 4 is not limited to this.

The first locking part 3 includes a cylindrical part 6, an anchor 5, aflange 7, and a plurality of projections 8 (two projections 8 areprovided in this embodiment). The anchor 5 has a flange shape extendingfrom the rear end of the cylindrical part 6 toward the outside. Theflange 7 extends from the leading end of the cylindrical part 6 towardthe outside. The projections 8 protrude from the leading end of thecylindrical part 6 in the direction parallel to the axis of the cylinderof the cylindrical part 6. These projections 8 face the opening 4 in thedirection of the diameter of the opening 4. The number of theprojections 8 is about 2 to about 4 for practical use.

Claw parts 8 a extending in the lateral direction are provided on theside faces of the projections 8 in the projecting direction. A space Sis formed between the claw parts 8 a and the flange 7. The extendingportion of the claw parts 8 a in the lateral direction diverges towardthe flange 7, in other words, the outer side faces of the projections 8form a tapered shape. Consequently, the projections 8 can be readilyinserted in the opening 4.

The first locking part 3 is formed as a single part using a syntheticresin. The projections 8 can be resiliently deformed in the approachingdirection.

Ferromagnetic particles such as ferrite particles are dispersed in thesynthetic resin forming the first locking part 3. Furthermore, amagnetization treatment is performed for the ferromagnetic particles tomagnetize the first locking part 3. Therefore, the first locking part 3can be magnetically held with a die used for molding the EA component 1.

As shown in FIG. 1 a, the cylindrical part 6 and the anchor 5 of thefirst locking part 3 are embedded in the EA component 1. In thisembodiment, the lower surface of the flange 7 and the surface of the EAcomponent 1 are disposed at the same level. Alternatively, the uppersurface of the flange 7 and the surface of the EA component 1 may bedisposed at the same level. Furthermore, the lower half of the flange 7may be embedded in the EA component 1, whereas the upper half of theflange 7 may be projected from the surface of the EA component 1. Forexample, as shown in FIG. 1 a, when the flange 7 is projected from thesurface of the EA component 1, the trim 2 is held between the claw parts8 a and the flange 7. Thus, the positional relationship between the EAcomponent 1 and the trim 2 in the approaching or separating direction(i.e., in the vertical direction in FIG. 1 a) is exclusively defined.

FIG. 1 a shows only a single first locking part 3. However, two or moreof the first locking parts 3 may be provided according to the dimensionor the shape of the EA component 1. The positions of the first lockingparts 3 are also determined according to the dimension or the shape ofthe EA component 1.

In order to attach the EA component 1 with the first locking part 3 tothe trim 2, the EA component 1 with the first locking part 3 is set onthe trim 2 while the projections 8 are inserted in the opening 4. Whenthe EA component 1 is pressed on the trim 2, the projections 8 arepressed into the opening 4. The claw parts 8 a are pressed on the innerperiphery of the opening 4. As a result, the projections 8 are insertedin the opening 4 while bending in the approaching direction. After theclaw parts 8 a pass through the opening 4, the shape of the projections8 is resiliently returned to the original shape. As a result, the sideface of each projection 8 is resiliently pressed on the inner peripheryof the opening 4. In addition, the claw parts 8 a and the flange 7 holdthe edge of the opening 4 disposed in the space S. Thus, the EAcomponent 1 can be attached to the trim 2 by only a single step ofoverlapping the EA component 1 having the first locking part 3 with thetrim 2. Accordingly, the efficiency of the attachment work issignificantly improved. In addition, the plurality of the projections 8of the first locking part 3 are resiliently pressed on the innerperiphery of the opening 4, and the claw parts 8 a of the projections 8and the flange 7 hold the edge of the opening 4. As a result, the EAcomponent 1 moves in the direction neither parallel nor orthogonal tothe surface of the trim 2. This structure provides a very reliableattachment of the EA component 1.

As shown in FIG. 1 a, the cylindrical part 6 and the anchor 5 of thefirst locking part 3 are embedded in the EA component 1. In thisstructure, the first locking part 3 does not pierce the EA component 1and a sufficient thickness of the EA component 1 is provided even in thevicinity of the first locking part 3. Therefore, excellentcharacteristics of shock absorption by the EA component 1 can beprovided even in the vicinity of the first locking part 3.

According to this attachment structure of the EA component 1, anyarrangement or any number of the first locking parts 3 and the openings4 may be used. Thus, any EA component having various shapes can bereliably attached to the trim by a simple method. Even when a flexibleEA component is used, the EA component can be reliably fixed byincreasing the number of the first locking parts 3 and the openings 4.

A method for producing the EA component 1 with the first locking part 3will now be described with reference to FIGS. 2 a and 2 b. A dieincluding a lower die 10 and an upper die 11 is used. The first lockingpart 3 is held on the surface of the cavity of the upper die 11 inadvance, and a synthetic resin material is supplied in the cavity toform the EA component 1 with the first locking part 3. For example, whenthe synthetic resin material is composed of a urethane, a stock solutionof the urethane is supplied in the lower die 10 and is foamed.Alternatively, an injection foam molding may be used.

A recess 12 that receives the projections 8 of the first locking part 3is provided in the upper die 11, which holds the first locking part 3. Aring 13 is provided at the inlet of the recess 12. The ring 13 iscomposed of a ferromagnetic material, for example, an alloy such as aniron-cobalt alloy or a ceramic such as ferrite. Either the ring 13 orthe first locking part 3 is magnetized in advance so that the firstlocking part 3 can be magnetically held with the ring 13. The ring 13 isnormally magnetized. The ring 13 may be composed of an electromagnet.

The above forming is performed while the upper surface of the flange 7is magnetically held with the lower surface of the ring 13. After thesynthetic resin is cured in the die to a predetermined degree, themolded article is ejected from the die to prepare the EA component 1with the first locking part 3.

Since the flange 7 is closely contacted with the ring 13 by magneticattraction, the synthetic resin does not flow in the space between theflange 7 and the ring 13. Thus, the generation of a burr can beprevented.

The embodiment shown in FIGS. 1 a and 1 b is an example of the firstaspect. The first aspect also includes other embodiments. For example,the shape of the flange 7 or the anchor 5 may have a shape other thanthat in the figures.

As described above, according to the first aspect, an EA component canbe readily attached to a member such as a trim. According to the presentinvention, the characteristics of shock absorption by the EA componentcan be improved. In addition, the EA component can be reliably attachedto the member regardless of the shape, the dimension, and the hardnessof the EA component.

A preferred embodiment of a second aspect will now be described withreference to FIGS. 5 a to 6 b. FIG. 5 a is a cross-sectional view in thesubstantially horizontal direction showing an attachment structure of anEA component according to this embodiment. FIG. 5 b is a longitudinalcross-section of a locking piece serving as a first locking part used inthis attachment structure of the EA component. FIG. 5 c is a perspectiveview of the locking piece. FIG. 6 a is a cross-sectional view showing amethod for producing the EA component with the locking piece. FIG. 6 bis an enlarged view of a part of FIG. 6 a.

Referring to FIG. 5 a, the sheet-shaped EA component 1 composed of asynthetic resin such as rigid urethane foam is attached to the trim 2 (adoor trim in this embodiment) serving as a member, with a locking piece3A therebetween. In this embodiment, the opening 4 serving as the secondlocking part is provided in the trim 2. The locking piece 3A is engagedwith the opening 4. Although the opening 4 preferably has a round shape,the shape of the opening 4 is not limited to this.

The locking piece 3A includes the cylindrical part 6, the anchor 5, theflange 7, a plurality of projections 8 (four projections 8 are providedin this embodiment), and a surrounding wall 9. The anchor 5 has a flangeshape extending from the rear end of the cylindrical part 6 toward theoutside. The flange 7 extends from the leading end of the cylindricalpart 6 toward the outside. The projections 8 protrude from the leadingend of the cylindrical part 6 in the direction parallel to the axis ofthe cylinder of the cylindrical part 6. The surrounding wall 9 isdisposed so as to surround the outside of a group of the projections 8.The surrounding wall 9 protrudes from the flange 7 in the same directionas that of the projections 8. The plurality of projections 8 (fourprojections 8 are provided in this embodiment) are provided so as toform an interval in the circumferential direction of the opening 4. Thenumber of the projections 8 is about 2 to about 4 for practical use.

Claw parts 8 a extending in the lateral direction are provided on theside faces of the projections 8 in the projecting direction. Theextending portion of the claw parts 8 a in the lateral directiondiverges toward the flange 7, in other words, the outer side faces ofthe projections 8 form a tapered shape. Consequently, the projections 8can be readily inserted in the opening 4.

The surrounding wall 9 has a ring shape. The height of the surroundingwall 9 is smaller than the distance between the flange 7 and the lowerend of the claw parts 8 a. As a result, a space S is formed between theclaw parts 8 a and the flange 7.

The locking piece 3A is formed as a single part using a synthetic resin.The projections 8 can be resiliently deformed in the centripetaldirection.

As shown in FIG. 5 a, the cylindrical part 6 and the anchor 5 of thelocking piece 3A are embedded in the EA component 1. In this embodiment,the upper surface of the flange 7 disposed at the outer periphery of thesurrounding wall 9 is embedded in the EA component 1. Alternatively,this portion may be exposed on the surface of the EA component 1. In anycase, the upper end of the surrounding wall 9 is either disposed at thesame level as the surface of the EA component 1 or projected from thesurface of the EA component 1. The edge of the opening 4 of the trim 2is held between the upper end of the surrounding wall 9 and the clawparts 8 a. Thus, the positional relationship between the EA component 1and the trim 2 in the approaching or separating direction (i.e., in thevertical direction in FIG. 5 a) is exclusively defined.

FIG. 5 a shows only a single locking piece 3A. However, two or more ofthe locking pieces 3A may be provided according to the dimension or theshape of the EA component 1. The positions of the locking pieces 3A arealso determined according to the dimension or the shape of the EAcomponent 1.

In order to attach the EA component 1 with the locking piece 3A to thetrim 2, the EA component 1 with the locking piece 3A is set on the trim2 while the projections 8 are inserted in the opening 4. When the EAcomponent 1 is pressed on the trim 2, the projections 8 are pressed intothe opening 4. The claw parts 8 a are pressed on the inner periphery ofthe opening 4. As a result, the projections 8 are inserted in theopening 4 while bending in the approaching direction. After the clawparts 8 a pass through the opening 4, the shape of the projections 8 isresiliently returned to the original shape. As a result, the side faceof each projection 8 is resiliently pressed on the inner periphery ofthe opening 4. In addition, the claw parts 8 a and the surrounding wall9 hold the edge of the opening 4 disposed in the space S. Thus, the EAcomponent 1 can be attached to the trim 2 by only a single step ofoverlapping the EA component 1 having the locking piece 3A with the trim2. Accordingly, the efficiency of the attachment work is significantlyimproved. In addition, side faces of the projections 8 of the lockingpiece 3A are resiliently fitted to the inner periphery of the opening 4,and the claw parts 8 a of the projections 8 and the upper end of thesurrounding wall 9 hold the edge of the opening 4. As a result, the EAcomponent 1 moves in the direction neither parallel nor orthogonal tothe surface of the trim 2. This structure provides a very reliableattachment of the EA component 1.

As shown in FIG. 5 a, the cylindrical part 6 and the anchor 5 of thelocking piece 3A are embedded in the EA component 1. In addition, thecylindrical part 6 and the anchor 5 are disposed only in about half (forexample, 30% to 50%) of the EA component 1 in the thickness direction.In this structure, the locking piece 3A does not pierce the EA component1 and a sufficient thickness of the EA component 1 is provided even inthe vicinity of the locking piece 3A. Therefore, excellentcharacteristics of shock absorption by the EA component 1 can beprovided even in the vicinity of the locking piece 3A.

According to this attachment structure of the EA component 1, anyarrangement or any number of the locking pieces 3A and the openings 4may be used. Thus, any EA component having various shapes can bereliably attached to the trim by a simple method. Even when a flexibleEA component is used, the EA component can be reliably fixed byincreasing the number of the locking pieces 3A and the openings 4.

A method for producing the EA component 1 with the locking pieces 3Awill now be described with reference to FIGS. 6 a and 6 b. A dieincluding the lower die 10 and an upper die 11A is used. The lockingpieces 3A is held on the surface of the cavity of the upper die 11A inadvance, and a synthetic resin material is supplied in the cavity toform the EA component 1 with the locking pieces 3A. For example, whenthe synthetic resin material is composed of a urethane, a stock solutionof the urethane is supplied in the lower die 10 and is foamed.Alternatively, an injection foam molding may be used.

A recess 12 that receives the projections 8 of the locking piece 3A isprovided in the upper die 11A, which holds the locking piece 3A. Anannular groove 13A in which the surrounding wall 9 is tightly fitted isprovided at the inlet of the recess 12. The locking piece 3A can be heldwith the upper die 11A by tightly fitting the surrounding wall 9 in thegroove 13A. In this embodiment, as shown in FIG. 6 b, when thesurrounding wall 9 is fitted in the groove 13A, the upper surface of theflange 7 disposed at the outside of the surrounding wall 9 is closelycontacted with the lower surface of the upper die 11A. According to thisstructure, the locking piece 3A does not tilt and is reliably held withthe upper die 11A.

The above forming is performed while the locking piece 3A is held withthe upper die 11A. After the synthetic resin is cured in the die to apredetermined degree, the molded article is ejected from the die toprepare the EA component 1 with the locking piece 3A.

The surrounding wall 9 is tightly fitted in the groove 13A, and inaddition, the flange 7 is closely contacted with the lower surface ofthe upper die 11A. This structure prevents the synthetic resin fromflowing on the top face of the surrounding wall 9 or in the inside ofthe surrounding wall 9. Thus, the generation of a burr can be prevented.

The above embodiment is an example of the second aspect. The secondaspect also includes embodiments other than that in the figures. Forexample, the shape of the flange 7 or the anchor 5 may have a shapeother than that in the figures.

As described above, according to the second aspect, an EA component canbe readily attached to a member such as a trim. According to the presentinvention, the characteristics of shock absorption by the EA componentcan be improved. In addition, the EA component can be reliably attachedto the member regardless of the shape, the dimension, and the hardnessof the EA component.

Embodiments of a third aspect will now be described with reference toFIGS. 7 a to 13 b.

FIG. 7 a is a cross-sectional view in the substantially horizontaldirection showing an attachment structure of an EA component accordingto an embodiment of the third aspect. FIG. 7 b is a perspective view ofa second locking part of the attachment structure of the EA component.FIG. 7 c is a perspective view of a first locking part of the attachmentstructure of the EA component. FIG. 10 is a cross-sectional view showinga method for producing the EA component with the first locking part.

Referring to FIG. 7 a, an EA component 41 composed of a synthetic resinsuch as rigid urethane foam is attached to a second locking part 43 of atrim 42 (a door trim in this embodiment) serving as a member. In thisembodiment, a first locking part 44 is provided in the EA component 41and the second locking part 43 is engaged with the first locking part44.

The second locking part 43 includes a pair of projections 48 provided onthe surface of the trim 42.

Claw parts 48 a extending in the lateral direction are provided on theside faces of the projections 48 in the projecting direction. The rearend of the projections 48 forms semicircular column parts 48 b. Theextending portion of the claw parts 48 a in the lateral directiondiverges toward the semicircular column parts 48 b. Thus, theprojections 48 form a tapered shape. Consequently, the projections 48can be readily inserted in an opening 52 of the first locking part 44,which will be described later.

The projections 48 are composed of a resilient synthetic resin. Theprojections 48 can be resiliently deformed in the approaching direction.Although the number of the projections 48 in FIGS. 7 a and 7 b is two,the number may be three or more. The number of the projections 48 ispreferably 2 to 6 for practical use.

The first locking part 44 includes a cylindrical part 46, an anchor 45,and a flange 47. The anchor 45 has a flange shape extending from therear end of the cylindrical part 46 toward the outside. The flange 47extends from the leading end of the cylindrical part 46 toward theoutside. The cylindrical opening 52 piercing the flange 47, thecylindrical part 46, and the anchor 45 is provided in the first lockingpart 44 in the direction of the central axis. A groove 53 is provided inthe inner periphery of the cylindrical opening 52 in the circumferentialdirection. The distance (length) from the outer surface of the flange 47to the groove 53 is equal to the length of the semicircular column parts48 b of the second locking part 43. The groove 53 preferably has a depthof about 0.2 to about 2 mm.

Ferromagnetic particles such as ferrite particles may be dispersed inthe synthetic resin forming the first locking part 44. Thus, the firstlocking part 44 may be more strongly held with a die used for moldingthe EA component 41 by a magnetic force.

As shown in FIG. 7 a, the cylindrical part 46 and the anchor 45 of thefirst locking part 44 are embedded in the EA component 41. In thisembodiment, the lower half of the flange 47 is embedded in the EAcomponent 41, whereas the upper half of the flange 47 is projected fromthe surface of the EA component 41. Alternatively, the lower surface ofthe flange 47 and the surface of the EA component 41 may be disposed atthe same level. The upper surface of the flange 47 and the surface ofthe EA component 41 may be disposed at the same level. However, forexample, as shown in FIG. 7 a, when the upper surface of the flange 47is projected from the surface of the EA component 41, a space is formedbetween the trim 42 and the EA component 41. In such a case, regardlessof the surface smoothness of the EA component 41, the trim 42 can beclosely contacted with the flange 47 directly.

FIG. 7 a shows only a single first locking part 44. However, two or moreof the first locking parts 44 may be provided according to the dimensionor the shape of the EA component 41. The positions of the first lockingparts 44 are also determined according to the dimension or the shape ofthe EA component 41.

In order to attach the EA component 41 with the first locking part 44 tothe trim 42, the EA component 41 with the first locking part 44 is seton the trim 42 while the projections 48 are inserted in the opening 52.When the EA component 41 is pressed on the trim 42, the projections 48are pressed into the opening 52. The claw parts 48 a are pressed on theinner periphery of the opening 52. As a result, the projections 48 areinserted in the opening 52 while bending in the approaching direction.When the claw parts 48 a reach the groove 53, the shape of theprojections 48 is resiliently returned to the original shape. As aresult, the claw parts 48 a and the trim 42 hold the edge of the groove53. The outer periphery of the semicircular column parts 48 b of theprojections 48 are fitted to the inner periphery of the opening 52 ofthe first locking part 44.

Thus, the EA component 41 can be attached to the trim 42 by only asingle step of overlapping the EA component 41 having the first lockingpart 44 with the trim 42. Accordingly, the efficiency of the attachmentwork is significantly improved. In addition, the claw parts 48 a of theprojections 48 and the trim 42 hold the edge of the groove 53, and theouter periphery of the semicircular column parts 48 b are fitted to theinner periphery of the opening 52. As a result, the EA component 41moves in the direction neither parallel nor orthogonal to the surface ofthe trim 42. This structure provides a very reliable attachment of theEA component 41.

As shown in FIG. 7 a, a part of the flange 47, the cylindrical part 46,and the anchor 45 of the first locking part 44 are embedded in the EAcomponent 41. In this structure, the first locking part 44 does notpierce the EA component 41 and a sufficient thickness of the EAcomponent 41 is provided even in the vicinity of the first locking part44. Therefore, excellent characteristics of shock absorption by the EAcomponent 41 can be provided even in the vicinity of the first lockingpart 44.

According to this attachment structure of the EA component 41, anyarrangement or any number of the second locking parts 43 and the firstlocking parts 44 may be used. Thus, any EA component having variousshapes can be reliably attached to the trim by a simple method. Evenwhen a flexible EA component is used, the EA component can be reliablyfixed by increasing the number of the second locking parts 43 and thefirst locking parts 44.

The inside diameter (i.e., diameter) of the opening 52 is preferablyabout 5 to about 30 mm. An excessively small inside diameter decreasesthe attachment strength of the EA component and prevents the projections48 from being inserted smoothly. On the other hand, an excessively largeinside diameter is not economical. The length (i.e., distance) from theinlet of the opening 52 to the edge of the groove 53 is preferably about10 to about 30 mm. When this length is excessively small, a burrgenerated in the molding of the EA component may reach the groove. Whenthis length is excessively large, the projections 48 must also beunnecessarily long.

A method for producing-the EA component 41 with the first locking part44 will now be described with reference to FIG. 10. A die including alower die 50 and an upper die 51 is used. The first locking part 44 isheld in a protrusion 51A of the upper die 51 in advance, and a syntheticresin material is supplied in the cavity to form the EA component 41with the first locking part 44. For example, when the synthetic resinmaterial is composed of a urethane, a stock solution of the urethane issupplied in the lower die 50 and is foamed. Alternatively, an injectionfoam molding may be used. The first locking part 44 is normally heldwith the protrusion 51A by a frictional force. Alternatively, asdescribed above, the first locking part 44 may be held with theprotrusion 51A by a magnetic force.

The above embodiment is an example of the third aspect. The presentinvention also includes embodiments other than that in the figures. Forexample, as will be described in the following, the shape of the flangeor the anchor may have a shape other than that in FIGS. 7 a to 7 c.

FIGS. 8 a and 8 b are partial perspective views showing two examples ofthe leading end of a first locking part according to other embodimentsof the third aspect. FIGS. 9 a and 9 b are partial perspective viewsshowing two examples of the rear end of a first locking part accordingto other embodiments of the third aspect. The same reference numerals asthose in FIGS. 7 a and 7 c indicate the same parts.

A first locking part 44A in FIG. 8 a does not include a flange. Thisfirst locking part 44A is preferably used in, for example, an inclinedplane of an EA component or a place that does not have a sufficient areato provide a flange.

A first locking part 44B in FIG. 8 b includes a tapered portion 47Bdisposed in the inner periphery of a flange 47A. The tapered portion 47Btapers from the upper surface of the flange 47A to the rear end of thefirst locking part 44B. When this first locking part 44B is used, theprojections 48 of the second locking part 43 are led to the opening 52with the tapered portion 47B. Therefore, the EA component can be readilyattached to the trim.

According to a first locking part 44C in FIG. 9 a, four notches 45 a areprovided in a circular anchor 45A. The first locking part 44C providesthe following advantage: In the production of the EA component, a stocksolution of, for example, a urethane is supplied in the lower die and isfoamed. In this step, the urethane or the like is readily provided onthe upper surface of the anchor 45A through the notches 45 a. As aresult, the anchor 45A is strongly bonded with the EA component 41.

According to a first locking part 44D in FIG. 9 b, an anchor 45B has amushroom-like shape in which the periphery tapers toward the rear end.In such a case, since the upper surface of the anchor 45B has asufficient area, an excellent anchoring effect is provided. Furthermore,since the anchor 45B has the shape in which the periphery tapers fromthe upper surface to the rear end, the following advantage is provided:In the production of the EA component, a stock solution of, for example,a urethane is foamed. In this step, the urethane or the like is smoothlyfoamed from the rear end side of the anchor 45B toward the upper surfaceand is then readily provided toward the upper surface of the anchor 45B.As a result, the EA component 41 is strongly bonded with the anchor 45B.

FIG. 11 a is a cross-sectional view in the substantially horizontaldirection showing an attachment structure of an EA component accordingto an embodiment of the third aspect. FIG. 11 b is a cross-sectionalview taken along line XI-XI in FIG. 11 a. FIG. 12 a is a perspectiveview of a second locking part in the attachment structure of the EAcomponent. FIG. 12 b is a perspective view of a first locking part inthe attachment structure of the EA component.

Referring to FIG. 12 a, a second locking part 60 includes a pair ofprojections 62 provided on the surface of the trim 42.

These projections 62 substantially have a plate shape and are disposedsuch that the plate faces face each other. Claw parts 62 a are providedon the outer plate faces of the projections 62 so as to extend in theopposite direction with respect to each other. The rear end of theprojections 62 forms rectangular column parts 62 b. The extendingportion of the claw parts 62 a in the lateral direction diverges towardthe rectangular column parts 62 b. In other words, the thickness of theplate forming the projections 62 tapers toward the leading end.Consequently, the projections 62 can be readily inserted in an opening75 of a first locking part 70, which will be described later. 107Referring to FIG. 12 b, the first locking part 70 includes a rectangulartube 73, an anchor 74, a tapered portion 72, and a frame 71. The anchor74 has a flange shape extending from the rear end of the rectangulartube 73 toward the outside. The tapered portion 72 diverges from theleading end of the rectangular tube 73 toward the trim 42. The frame 71extends from the leading end of the tapered portion 72 in the directionparallel to the central axis of the rectangular tube 73.

Referring to FIGS. 11 a and 11 b, the opening 75 of the first lockingpart 70 pierces in the direction of the central axis of the rectangulartube 73. A groove 76 is provided on the inner surface of the opening 75.The groove 76 extends in the direction orthogonal to the central axis ofthe rectangular tube 73. The opening 75 has a rectangular section whencut in the direction orthogonal to the above central axis. The groove 76is provided around the four sides of the rectangle. The groove 76 isprovided such that the cross-sectional area of the opening 75 adjacentto the anchor 74 is larger than that of the opening 75 adjacent to thetapered portion 72. In this embodiment, the claw parts 62 a are engagedwith two faces of the groove 76 disposed along a pair of long sides ofthe rectangle.

The anchor 74, the rectangular tube 73, the tapered portion 72, and thelower half of the frame 71 of the first locking part 70 are embedded inthe EA component 41, whereas the upper half (adjacent to the leadingend) of the frame 71 is projected from the surface of the EA component41.

According to this embodiment, the EA component 41 is attached to thetrim 42 by inserting the second locking part 60 in the first lockingpart 70. When the second locking part 60 is inserted in the firstlocking part 70, the claw parts 62 a and the trim 42 hold the edge ofthe groove 76.

In this embodiment, as shown in FIG. 11 b, the width of the projections62 is almost the same as the long sides of the rectangle disposeddirectly on the groove 76 of the opening 75. As a result, when thesecond locking part 60 is engaged with the first locking part 70, thedisplacement of the second locking part 60 in the horizontal directionin FIG. 11 b can be prevented.

In the attachment structure of the EA component according to thisembodiment, because of the substantially rectangular column shape, thesecond locking part 60 can be readily molded, compared with the secondlocking part 43 shown in FIG. 7 b. In addition, since the first lockingpart 70 includes the tapered portion 72, the second locking part 60 canbe readily inserted in the first locking part 70.

According to this embodiment, since the leading end of the first lockingpart 70 is projected from the surface of the EA component 41, a space isformed between the trim 42 and the EA component 41. As a result,regardless of the surface smoothness of the EA component 41, the trim 42can be closely contacted with the frame 71 directly. Accordingly, theattachment accuracy of the trim 42 and the frame 71 depends only on thefitting accuracy of the second locking part 60 and the first lockingpart 70. Therefore, a deformation or a variation in the EA component 41within a dimensional tolerance does not affect the attachment.

Although the outer surfaces of the first locking part 70 according tothe above embodiment include an angular shape, the first locking part 70may have rounded corners. For example, four corners of the anchor 74,four corners of the rectangular tube 73, and four corners of the frame71 may be rounded corners. Such a shape provides the followingadvantage: In order to produce the EA component 41 with the firstlocking part 70, the first locking part 70 is held in a die in advanceand a stock solution of, for example, a urethane is supplied in the dieand is foamed. In this step, since the foamed urethane is readilyprovided around the rounded portions of the first locking part, theurethane is satisfactorily filled in the vicinity of the first lockingpart. As a result, the first locking part is strongly bonded with the EAcomponent.

FIG. 13 a is a plan view of a trim used in an attachment structure of anEA component according to an embodiment of the third aspect. FIG. 13 bis a cross-sectional view showing the state wherein a second lockingpart 60 is engaged with a first locking part 70. FIG. 13 b is across-sectional view taken along line XIII-XIII in FIG. 13 a showing thestate wherein the second locking part is engaged with the first lockingpart, and shows a cross-section of the same part as that in FIG. 11 b.

According to this embodiment, a plurality of second locking parts 60 isprovided such that the directions of plate faces of plate-shapedprojections 62 of the second locking parts 60 are orthogonal withrespect to each other. Referring to FIG. 13 a, in the second lockingpart 60 disposed at the upper left, the plate faces of the projections62 are directed in the vertical direction (the Y direction) in thefigure. On the other hand, in the second locking part 60 disposed at thelower right, the plate faces of the projections 62 are directed in thehorizontal direction (the X direction) in the figure.

According to this embodiment, as shown in FIGS. 13 a and 13 b, the widthW of the projection 62 in the plate face direction (i.e., the width ofthe projection 62 in the direction orthogonal to the inserting directionin the opening 75) is smaller than the width at the position locateddirectly on the groove 76 of the opening 75 in the direction orthogonalto the inserting direction. As a result, a space is formed between theside edge of the projection 62 and the inner surface of the opening 75.

In the EA component 41 (not shown in FIGS. 13 a and 13 b), equivalentfirst locking parts 70 are disposed at the positions facing thecorresponding second locking parts 60. The second locking parts 60 areinserted in the corresponding first locking parts 70, thereby attachingthe EA component 41 to the trim 42.

According to this attachment structure of the EA component, as shown inFIG. 13 b, the width W of the projection 62 is smaller than the width ofthe opening 75. Therefore, even if the relative positions of the secondlocking part 60 and the corresponding first locking part 70 are somewhatoffset in the X direction or in the Y direction, the second locking part60 can be engaged with the first locking part 70.

Although FIG. 13 a shows two second locking parts 60, three or more ofthe second locking parts 60 may be provided on a trim.

In the above embodiments, only the top face of the first locking part 44or 70 is in contact with the trim 42 and the EA component 41 is out ofcontact with the trim 42 as a whole. Alternatively, a part of the EAcomponent 41 may be brought into contact with the trim 42 directly. Thisstructure stabilizes the attachment of the EA component.

Embodiments of a fourth aspect will now be described with reference toFIGS. 14 and 15. FIG. 14 is an exploded view of an attachment structureof an EA component according to an embodiment of the fourth aspect. FIG.15 is a cross-sectional view showing a method for producing the EAcomponent with a planar fastener.

Referring to FIG. 14, a non-woven fabric 92 is bonded on the surface ofa trim 91 with an adhesive such as a hot melt adhesive. In thisembodiment, an EA component 93 is composed of rigid urethane foam andhas a planar fastener 94 thereon. The planar fastener 94 includes a flatbase 94 a, engaging projections 94 b extending from the top face of thebase 94 a, and anchors 94 c extending from the back-side of the base 94a.

Each of the engaging projections 94 includes a narrow rod disposed atthe rear end and an expanding head disposed at the leading end. Theexpanding head extends in the lateral direction from the narrow roddisposed at the rear end. The expanding head has a tapered shape so thatthe dimension of the expanding head is gradually decreased toward theleading end. This tapered expanding head extends in the lateraldirection from the narrow rod. Therefore, when the engaging projections94 b are pressed into the non-woven fabric 92, the expanding heads areentwined with the fabric in the non-woven fabric 92. As a result, theengaging projections 94 b do not separate from the non-woven fabric 92.

The planar fastener 94 is provided such that the top face of the base 94a is disposed at the same level as the surface of the EA component 93.The anchors 94 c are embedded in the EA component 93. Each of theanchors 94 c includes a flange-shaped expanding portion at the leadingend. The anchors 94 c prevent the planar fastener 94 from separatingfrom the EA component 93.

The EA component 93 with the planar fastener 94 is pressed on thenon-woven fabric 92 disposed on the surface of the trim 91 so as toinsert the engaging projections 94 b in the non-woven fabric 92. Becauseof the tapered shape, the engaging projections 94 b are inserted in thenon-woven fabric 92 smoothly. The inserted engaging projections 94 b areentwined with the fabric in the non-woven fabric 92. Thus, the EAcomponent is combined with the non-woven fabric 92, with the planarfastener 94 therebetween. The height of the engaging projections 94 b issmaller than the thickness of the non-woven fabric 92.

The number of the planar fasteners 94 and the arrangement thereof aredetermined according to the dimension or the shape of the EA component93.

As described above, according to this embodiment, the EA component 93with the planar fastener 94 can be attached to the trim 91 by onlypressing the EA component 93 on the non-woven fabric 92 provided on thesurface of the trim 91. Accordingly, the efficiency of the attachmentwork is excellent.

In addition, as shown in FIG. 14, the anchors 94 c of the planarfastener 94 do not pierce the EA component 93. In other words, theheight of the anchors 94 c is sufficiently smaller than the thickness ofthe EA component 93. For example, the height of the anchors 94 c is 50%or less of the thickness of the EA component 93. Therefore, a sufficientthickness of the EA component 93 is provided even in the vicinity of theplanar fastener 94. As a result, satisfactory characteristics of shockabsorption can be provided even in the vicinity of the planar fastener94.

A method for producing the EA component 93 with the planar fastener 94will now be described with reference to FIG. 15. A die 100 having arecess 101 is used. The recess 101 is provided on the cavity andreceives the engaging projections 94 b. The engaging projections 94 bare disposed in the recess 101 so that the recess 101 is covered withthe base 94 a. In this state, a stock solution of a urethane is suppliedin the die 100 and is foamed.

The planar fastener 94 is composed of a synthetic resin. Preferably,magnetic particles such as ferrite particles are mixed in the syntheticresin, and in addition, a magnet is provided in the die. Thus, theplanar fastener 94 is magnetically held with the die 100. In such acase, since the base 94 a of the planar fastener 94 reliably covers therecess 101, the flowing of the urethane in the recess 101 can beprevented. Furthermore, even when the planar fastener 94 receives a foampressure, the planar fastener 94 does not move on the surface of the die100.

Although the trim 91 and the EA component 93 have a planar surface inFIG. 14, the trim 91 and the EA component 93 may have a curved surface.Although the engaging projections 94 b have a mushroom shape, theengaging projections 94 b may have a J letter shape.

In FIG. 14, in the base 94 a of the planar fastener 94, the surfacehaving the engaging projections 94 b is disposed at the same level asthe surface of the surrounding EA component 93. Alternatively, thesurface of the base 94 a having the engaging projections 94 b may bepartially projected from the surface of the surrounding EA component 93or further embedded in the surface of the EA component 93.

As described above, according to the fourth aspect, an EA component canbe readily attached to a member such as a trim. According to the presentinvention, the characteristics of shock absorption by the EA componentcan be improved. In addition, the EA component can be reliably attachedto the member regardless of the shape, the dimension, and the hardnessof the EA component.

1. An attachment structure of an EA component for attaching the EAcomponent to a member, wherein: the EA component is attached to themember by engaging a first locking part that is integrated with the EAcomponent with a second locking part provided in the member; the EAcomponent comprises a urethane foam; the first locking part isintegrated with the urethane foam; and the first locking part comprisesa projection that engages with the second locking part and a surroundingwall that surrounds the rear end portion of the projection.
 2. Theattachment structure of an EA component according to claim 1, whereinthe first locking part can be resiliently deformed, and when engagedwith the second locking part, the first locking part is resilientlydeformed and is then resiliently restored to engage with the secondlocking part.
 3. The attachment structure of an EA component accordingto claim 2, wherein the second locking part is an opening.
 4. Theattachment structure of an EA component according to claim 3, whereinthe first locking part comprises a claw part engaged with the edge ofthe opening.
 5. The attachment structure of an EA component according toclaim 4, wherein the first locking part comprises a projectionprojecting from the EA component and the claw part is provided on theside face of the projection in the projecting direction.
 6. Theattachment structure of an EA component according to claim 5, wherein aplurality of the projections is provided along the edge of the opening.7. The attachment structure of an EA component according to claim 5,wherein the first locking part comprises a flange and the edge of theopening is held between the flange and the claw part.
 8. The attachmentstructure of an EA component according to claim 5, wherein a base of thefirst locking part is embedded in the EA component.
 9. The attachmentstructure of an EA component according to claim 8, wherein the base ofthe first locking part is embedded so as not to pierce the EA component.10. The attachment structure of an EA component according to claim 1,wherein the first locking part can be magnetically held with a die usedfor molding the EA component.
 11. The attachment structure of an EAcomponent according to claim 1, wherein the projection can beresiliently deformed, and when engaged with the second locking part, theprojection is resiliently deformed and is then resiliently restored toengage with the second locking part.
 12. The attachment structure of anEA component according to claim 11, wherein the second locking part isan opening.
 13. The attachment structure of an EA component according toclaim 12, wherein the projection comprises a claw part engaged with theedge of the opening.
 14. The attachment structure of an EA componentaccording to claim 13, wherein the claw part is provided on the sideface of the projection in the projecting direction.
 15. The attachmentstructure of an EA component according to claim 14, wherein a pluralityof the projections is provided along the edge of the opening.
 16. Theattachment structure of an EA component according to claim 14, whereinthe first locking part comprises a flange, the projection and thesurrounding wall are disposed so as to be projected from the flange, andthe edge of the opening is held between the leading end of thesurrounding wall and the claw part.
 17. An attachment structure of an EAcomponent for attaching the EA component to a member, wherein: the EAcomponent is attached to the member by engaging a first locking partthat is integrated with the EA component with a second locking partprovided in the member; the first locking part comprises a projectionthat engages with the second locking part and a surrounding wall thatsurrounds the rear end portion of the projection; and a base of thefirst locking part is embedded in the EA component.
 18. The attachmentstructure of an EA component according to claim 17, wherein the base ofthe first locking part is embedded so as not to pierce the EA component.19. The attachment structure of an EA component according to claim 1,wherein the surrounding wall has an annular shape.
 20. The attachmentstructure of an EA component according to claim 1, wherein the urethanefoam is not provided in the inside of the surrounding wall.
 21. Alocking piece for attaching an EA component comprising: a base embeddedin the EA component; a flange provided at one end of the base; aplurality of projections projected from the flange, the projectionsbeing able to be resiliently deformed, and the projections beinginserted in an opening for attaching the EA component; claw partsprovided on the side face of the projections, the claw parts being ableto be engaged with the edge of the opening; and a surrounding wallprojected from the flange in the same direction as that of theprojections, the surrounding wall surrounding the rear end portion ofthe projections.
 22. The locking piece according to claim 21, whereinthe claw parts of the projections are disposed at a further end of theleading end of the surrounding wall in the projecting direction.
 23. Anattachment structure of an EA component for attaching the EA componentto a member, wherein: the EA component is attached to the member byengaging a first locking part that is integrated with the EA componentwith a second locking part provided in the member; the first lockingpart comprises a projection that engages with the second locking partand a surrounding wall that surrounds the rear end portion of theprojection; and the first locking part is a locking piece for attachingan EA component, the locking piece comprising: a base embedded in the EAcomponent; a flange provided at one end of the base; a plurality ofprojections projected from the flange, the projections being able to beresiliently deformed, and the projections being inserted in an openingfor attaching the EA component; claw parts provided on the side face ofthe projections, the claw parts being able to be engaged with the edgeof the opening; and a surrounding wall projected from the flange in thesame direction as that of the projections, the surrounding wallsurrounding the rear end portion of the projections.
 24. The attachmentstructure of an EA component according to claim 2, wherein the firstlocking part comprises a tube-shaped opening in which the second lockingpart is inserted and a groove provided in the inner periphery of thetube-shaped opening in the circumferential direction, and the secondlocking part is engaged with the groove.
 25. The attachment structure ofan EA component according to claim 24, wherein the second locking partcomprises a claw part engaging with the edge of the groove.
 26. Theattachment structure of an EA component according to claim 25, whereinthe second locking part is a projection projecting from the member andthe claw part is provided on the side face of the projection in theprojecting direction.
 27. The attachment structure of an EA componentaccording to claim 26, wherein a plurality of the projections isinserted in the single tube-shaped opening.
 28. The attachment structureof an EA component according to claim 26, wherein the edge of the grooveis held between the member and the claw part.
 29. The attachmentstructure of an EA component according to claim 26, wherein most of thefirst locking part is embedded in the EA component and only the leadingend face of the first locking part is projected from the EA component.30. The attachment structure of an EA component according to claim 29,wherein the first locking part is embedded so as not to pierce the EAcomponent.
 31. The attachment structure of an EA component according toclaim 24, wherein the tube-shaped opening is a cylindrical opening. 32.The attachment structure of an EA component according to claim 24,wherein the tube-shaped opening is a rectangular tube opening.
 33. Theattachment structure of an EA component according to claim 32, wherein asection of the rectangular tube opening in the direction orthogonal tothe central axis of the tube is a rectangle and the groove is providedin the direction of the long sides of the rectangle.
 34. The attachmentstructure of an EA component according to claim 33, wherein the EAcomponent is attached to the member with a plurality of pairs of thesecond locking parts and the first locking parts, and at least two pairsof the second locking parts and the first locking parts are disposedsuch that the directions of the long sides of the rectangle in therectangular tube opening are orthogonal with respect to each other. 35.The attachment structure of an EA component according to claim 33,wherein the width of the claw part in the direction parallel to thegroove is smaller than the width of the groove.
 36. The attachmentstructure of an EA component according to claim 24, wherein the inlet ofthe tube-shaped opening has a tapered shape gradually tapered toward theinside.
 37. The attachment structure of an EA component according toclaim 36, wherein the end of the inlet of the tube-shaped openingextends in the direction substantially parallel to the central axis ofthe tube.
 38. The attachment structure of an EA component according toclaim 24, wherein a part of the EA component is in contact with themember.
 39. The attachment structure of an EA component according toclaim 1, wherein the member is a trim of an automobile.
 40. Theattachment structure of an EA component according to claim 1, wherein anon-woven fabric serving as the second locking part is provided on thesurface of the member, the surface to which the EA component beingattached, and a planar fastener serving as the first locking part isfixed on the surface of the EA component, the planar fastener beingintegrated with the EA component during the molding of the EA componentwith foaming, and the EA component is attached to the surface of themember by entwining the planar fastener with the non-woven fabric. 41.The attachment structure of an EA component according to claim 40,wherein the planar fastener comprises engaging projections that areentwined with the non-woven fabric.
 42. The attachment structure of anEA component according to claim 40, wherein anchors are provided on theback-side of the planar fastener and the anchors are embedded in the EAcomponent.
 43. The attachment structure of an EA component according toclaim 42, wherein the anchors are embedded so as not to pierce the EAcomponent.
 44. The attachment structure of an EA component according toclaim 40, wherein the EA component comprises rigid urethane foam. 45.The attachment structure of an EA component according to claim 40,wherein the non-woven fabric is bonded on the surface of the member. 46.The attachment structure of an EA component according to claim 40,wherein the surface of the member is a back-side of a roof component ofan automobile.
 47. The attachment structure of an EA component accordingto claim 1, wherein the urethane foam is a rigid urethane.